EN BU Functional Safety. Supplementary manual for series SK 200E

Transcription

1 EN BU 0230 Functional Safety Supplementary manual for series SK 200E

2 Functional Safety Supplementary manual for series SK 200E Table of Contents 1 Introduction General Documentation Document History About this manual Other applicable documents Presentation conventions Warning information Other information Safety, installation and operating instructions Function description Safe shut-down methods Safe Pulse Block Switch-off of the 24 V supply Digital inputs (DIN1... DIN4) Safety functions Safe Torque Off, STO Safe Stop 1, SS Examples / Implementation STO function SS1 Function Simple restart block Example without safe shut-down method Ruling out wiring faults Assembly and installation Installation and assembly Electrical connection Wiring guidelines Mains connection Control cable connections Control terminal details Details of the safe shut-down method Safe shut-down method - Safe Pulse Block Operation with OSSD EMC Example operation of multiple devices Safe shut-down method - 24 V supply Operation at OSSD EMC Example operation of multiple devices 33 5 commissioning Commissioning steps for STO Commissioning of SS Selection of the safe shut-down method Validation Parameters Description of parameters Control terminals Additional parameters Operating status messages Additional information Protective switching devices Output voltage Switchingcapacityandcurrentload OSSD outputs, test pulses Safety categories BU 0230 EN-1217

3 Table of Contents IEC : IEC : IEC 61508: ISO : Technical Data Data for the safe pulse block Data for switching off the 24 V supply Data for the digital inputs Appendix Maintenance Instructions Repair information Service and commissioning information Documents and software Certificates Abbreviations BU 0230 EN

4 Functional Safety Supplementary manual for series SK 200E 1 Introduction 1.1 General Documentation Name: BU 0230 Part number: Series: Functional safety for frequency inverters from the series NORDAC Flex (SK 200E SK 235E) Scope of application: SK 205E, SK 210E, SK 215E, SK 230E, SK 235E Document History Issue Version Remarks Order number Software BU 0230, July 2009 V 1.1 R2 First issue / 3109 Further revisions: September 2009, February 2010, January 2011 For an overview of the amendments to the above editions: please refer to the January 2011 version (Part No.: No.: / 0311) BU 0230, July 2012 V 1.3 R2 Size 4 devices included / 2712 BU 0230, March 2017 V 2.1 R3 Update of technical data / 1217 (e.g PFH and SFF values). Transfer of certificates to 4 BU 0230 EN-1217

5 1 Introduction About this manual This manual is intended to help you with the commissioning of the "Safe Stop" function (STO or SS1) of a frequency inverter or motor starter from Getriebebau NORD GmbH & Co. KG (NORD). It is intended for all qualified electricians who plan, install and set up corresponding drive solutions ( Section 2 "Safety, installation and operating instructions"). The information in this manual assumes that the qualified electricians who are entrusted with this work are familiar with the handling of electronic drive technology, in particular with NORD devices. This manual only contains information and descriptions of the functional safety and additional information which is relevant for the functional safety of frequency inverters manufactured by Getriebebau NORD GmbH & Co. KG. 1.2 Other applicable documents This document is only valid in combination with the operating instructions for the frequency inverter which is used. Safe commissioning of the drive application depends on the availability of the information contained in this document.. A list of the documents can be found in Section 10.4 "Documents and software". The necessary documents can be found under Presentation conventions Warning information Warning information for the safety of the user and the bus interfaces are indicated as follows: DANGER This warning information warns against personal risks, which may cause severe injury or death. WARNING This warning information warns against personal risks, which may cause severe injury or death. CAUTION This warning information warns against personal risks, which may cause slight or moderate injuries. NOTICE This warning warns against damage to material Other information Information This information shows hints and important information. BU 0230 EN

6 Functional Safety Supplementary manual for series SK 200E 2 Safety, installation and operating instructions Before working on or with the device, please read the following safety instructions extremely carefully. Please pay attention to all other information from the device manual. Non-compliance can result in serious or fatal injuries and damage to the device or its surroundings. These safety instructions must be kept in a safe place! 1. General During operation and depending on the protection class of the devices, there may be live, bare, moving or rotating parts or hot surfaces. The device operates with a dangerous voltage. Dangerous voltage may be present at the supply lines, contact strips and PCBs of all connecting terminals (e.g. mains input, motor connection), even if the device is not working or the motor is not rotating (e.g. caused by electronic disable, jamming of the drive or a short circuit at the output terminals). The device is not equipped with a mains switch and is therefore always live when connected to the power supply. Even if the drive unit has been disconnected from the mains, a connected motor may rotate and possibly generate a dangerous voltage. If you come into contact with dangerous voltage such as this, there is a risk of an electric shock, which can lead to serious or fatal injuries. Unauthorised removal of covers, improper use, incorrect installation or operation causes a risk of serious personal injury or material damage. The heat sink and all other metal components can heat up to temperatures above 70 C. Touching parts such as this can result in local burns to the body parts concerned (cooling times and clearance from neighbouring components must be adhered to). Further information can be found in this documentation. All transportation, installation, commissioning and maintenance work must be carried out by qualified experts (pay attention to IEC 364 or CENELEC HD 384 or DIN VDE 0100 and IEC 664 or DIN VDE 0110 and the national accident prevention regulations). 2. Qualified experts For the purposes of these basic safety instructions, qualified personnel are persons who are familiar with the assembly, installation, commissioning and operation of this product and who have the relevant qualifications for their work. Furthermore, the device and the associated accessories may only be installed and started up by qualified electricians. An electrician is a person who, because of their technical training and experience, has sufficient knowledge with regard to switching on, switching off, isolating, earthing and marking power circuits and devices, proper maintenance and use of protective devices in accordance with defined safety standards. 3. Correct purpose of use general The frequency inverters are devices for industrial and commercial systems used for the operation of three-phase asynchronous motors with squirrel-cage rotors and Permanent Magnet Synchronous Motors PMSM. These motors must be suitable for operation with frequency inverters, other loads must not be connected to the devices. The devices are components intended for installation in electrical systems or machines. 6 BU 0230 EN-1217

7 2 Safety, installation and operating instructions Technical data and information for connection conditions can be found on the rating plate and in the documentation, and must be complied with. The devices may only be used for safety functions which are described and explicitly approved. CE-labelled devices fulfil the requirements of the Low Voltage Directive 2014/35/EU. The stated harmonized standards for the devices are used in the declaration of conformity. a. Supplement: Correct purpose of use within the European Union When installed in machines, the devices must not be commissioned (i.e. commencement of proper use) until it has been ensured that the machine fulfils the provisions of EC Directive 2006/42/EC (Machinery Directive); EN must also be complied with. Commissioning (i.e. start-up of proper use) is only permitted if the EMC directive (2014/30/EU) has been complied with. b. Supplement: Correct purpose of use outside the European Union The local conditions of the operator for the installation and commissioning of the device must be complied with at the usage location (see also "a) Supplement: Correct purpose of use within the European Union"). 4. Transport, storage The information in the manual regarding transport, storage and correct handling must be complied with. 5. Installation Ensure that the device and the motor are specified for the correct supply voltage. The installation and cooling of the equipment must be implemented according to the regulations in the corresponding documentation. The devices must be protected against impermissible loads. Especially during transport and handling, components must not be deformed and/or insulation distances must not be changed. Touching of electronic components and contacts must be avoided. The devices contain electrostatically sensitive components, which can be easily damaged by incorrect handling. Electrical components must not be mechanically damaged or destroyed (this may cause a health hazard!). 6. Electrical connection Installation and work must not be carried out unless the device has been disconnected from the voltage and at least 5 minutes has elapsed since the mains was switched off! (The equipment may continue to carry hazardous voltages for up to 5 minutes after being switched off at the mains). When working on live devices, the applicable national accident prevention regulations must be complied with (e.g. BGV A3, formerly VBG 4). The electrical installation must be implemented as per the applicable regulations (e.g. cable crosssection, fuses, earth lead connections). Further instructions can be found in the documentation. Information regarding EMC-compliant installation (such as shielding, earthing, location of filters and routing of cables) can be found in the documentation for the devices. CE marked devices must also comply with these instructions. Compliance with the limit values specified in the EMC regulations is the responsibility of the manufacturer of the system or machine. In case of a fault, insufficient earthing may cause an electric shock with possibly fatal consequences if the device is touched. Because of this, the device is only intended for permanent connection and may not be operated without effective earthing connections which comply with local regulations for large leakage currents (> 3.5 ma). BU 0230 EN

8 Functional Safety Supplementary manual for series SK 200E The voltage supply of the device may directly or indirectly put it into operation, or touching electrically conducting components may then cause an electric shock with possible fatal consequences. All phases of all power connections (e.g. power supply) must always be disconnected. 7. Operation Do not use defective devices or devices with defective or damaged housings or missing covers. Otherwise there is a risk of serious or fatal injuries caused by electric shock or bursting electrical components such as powerful electrolytic capacitors. Where necessary, systems in which the devices are installed must be equipped with additional monitoring and protective equipment according to the applicable safety requirements (e.g. legislation concerning technical equipment, accident prevention regulations, etc.). The parametrisation and configuration of the devices must be selected so that no hazards can occur. All covers must be kept closed during operation. With certain setting conditions, the device or the motor which is connected to it may start automatically when the mains are switched on. The machinery which it drives (press / chain hoist / roller / fan etc.) may then make an unexpected movement. This may cause various injuries, including to third parties. Before switching on the mains, secure the danger area by warning and removing all persons from the danger area. 8. Maintenance and repairs Live equipment components and power connections should not be touched immediately after disconnecting the devices from the power supply because of possible charged capacitors. Observe the applicable information signs located on the device. Further information can be found in this documentation. 9. Potentially explosive environment (ATEX) In order to operate or carry out installation work in potentially explosive environments (ATEX), the device must be approved and the relevant requirements and notes from the manual of the device must be complied with. Failure to comply can result in the ignition of an explosive atmosphere and fatal injuries. 8 BU 0230 EN-1217

9 3 Function description 3 Function description To avoid danger to persons and to prevent damage to material, machines must be able to be switched off safely. The frequency inverters stated in this document provide safe shut-down methods. The following basic explanation of the function of a frequency inverter serves to provide better understanding of the function of safe shut-down methods: The mains voltages are rectified and the resulting DC links circuit voltage is reconverted to AC according to the requirements of the operating status of the motor (frequency and voltage). The semiconductor switches of the inverter (T1 to T6) are controlled by a highly complex pulse pattern. This pulse pattern is generated by the micro-controller (µc) and amplified by the driver. The drivers convert the logic signals on the control voltages of the semiconductor switch. The semiconductor switches are switched via the control voltage and the pulse pattern is amplified and applied to the motor terminals. Due to the low-pass effect of the motor, a three-phase pulse width modulated sine wave voltage, a three-phase system, results from the pulsed voltage. The motor generates a torque. 1 I/O fast stop 2 Micro-controller 3 Logic 4 Driver 5 Undervoltage detection, current limitation 6 Input circuits 7 Option "safe pulse block" 8 DC/DC converter (only SK 2x0E) 9 DC/DC converter (only SK 2x5E) Figure 1: Structure of Safe Pulse Block, Size 1 to 3 BU 0230 EN

10 Functional Safety Supplementary manual for series SK 200E 1 I/O fast stop 2 Micro-controller 3 Logic 4 Driver 5 Input circuits 6 Option "safe pulse block" 7 Internal voltage (primary power)) 8 Control voltage Figure 2: Structure of safe pulse block, Size 4 By the use and combination of safe shut-down methods and digital inputs (DIN1... DIN4) the safetyrelated stop functions STO and SS1 as well as a simple restart block can be implemented with various safety and performance levels. 10 BU 0230 EN-1217

11 3 Function description 3.1 Safe shut-down methods With a safe shut-down method, the torque is switched off and a stop function is carried out. As this has priority over other control functions this stop-function is suitable for stopping in emergencies. This function is known as "Safe Torque Off" or STO. The safe switch-off of the torque according to the STO safety function depends on the interruption of the flow of current to the motor. The following switch-off methods are available for this: Safe Pulse Block "Switch-off of the 24 V supply" (only SK 205E and SK 215E) It is also possible to first stop the motor in a controlled manner and then to switch off the torque. This function is referred to as "Safe Stop 1" or SS Safe Pulse Block Devices equipped with a "Safe Pulse Block" have an additional DC/DC converter, which produces a 24V supply (Contacts 24V_SH, GND_SH) as either the supply voltage for the drivers or the control voltage for a mains unit which in turn produces the supply voltage for the drivers. If the external 24 V voltage is switched off then the DC/DC converter does not transmit any power to the drivers. As the drivers are now no longer supplied with power, no pulses reach the semiconductor switches (T1 to T6) of the inverter. The flow of current in the semiconductor switches and in the motor is interrupted i.e. after a certain reaction time of the electronics and the reduction time of the motor current, the motor does not develop a driving torque. The switch-off of the 24V supply via contacts 24V_SH, GND_SH must be carried out by a fail-safe switching device. For this, either the contact 24V_SH or the connection GND_SH contact may be disconnected from the 24V source. Preferably, the 24V_SH connection is disconnected Safety output Safety output Safety output Frequency inverter or or BU 0230 EN

12 Functional Safety Supplementary manual for series SK 200E Switch-off of the 24 V supply The 24 V mains unit used to supply the control electronics can also be used as a safe shut-down method (only for SK 205E and SK 215E). If the 24V supply (24 V, GND) is switched off, the micro-controller (µc) is disconnected from the supply voltage. As the micro-controller is responsible for the generation of the pulse pattern to control the semiconductor switches (T1 to T6), this method switches off all the semiconductor switches (T1 to T6). The flow of current in the semiconductor switches and in the motor is interrupted i.e. as with the "Safe Pulse Block", after a certain reaction time of the electronics and the reduction time of the motor current, the motor does not develop a driving torque. "Switch-off of the 24 V supply" (24V, GND) must also be carried out by means of a fail-safe switching device. In this case, the connection between the voltage source and the 24 V connection must be interrupted. Switch-off via GND is not possible, as the 24 V supply and the digital I/O have a common earth. If GND was switched off, there would still be a connection to earth via the digital I/O. Safety output Safety output Safety output Frequency inverter Information Devices with integrated-as interface For devices with an integrated AS interface (SK 225E and SK 235E) the 24 V supply cannot be used as a safe shut-down method "Switch-off of the 24 V supply" must be used. Information SK 2x0E, Size 4 The 24 V connection in Size 4 SK 200E, SK 210E, SK 220E and SK 230E frequency inverters which is used to supply the control electronics cannot be used as a safe shut-down method. Reason: The high voltage mains which is used in these devices would continue to supply the controller and the micro-controller even when the external 24 V supply is switched off. 12 BU 0230 EN-1217

13 3 Function description 3.2 Digital inputs (DIN1... DIN4) In order to implement a safety function, the digital inputs (DIN1... DIN4) can be used as auxiliary inputs, e.g. for the triggering of a braking process. It should be noted that the digital inputs only fulfil minimum safety requirements. A safe shut-down method is always required! The digital inputs, further I/Os and the 24 V supply have a common earth. This means that a digital input may only be switched off by disconnection of its connection. Switch-off via GND is not possible! Safety output Safety output Safety output Filter for OSSD (optional) Frequency inverter When operating with an OSSD a filter is only required for environments with high levels of interference. If only low levels of functional safety are required, the safety function can also be implemented with the digital inputs. It is recommended that this is only considered if the risk assessment has shown that slight (normally temporary) injuries could result on failure of the safety function (see also Section 8.2). In case of doubt, a safe shut-down method should always be used. BU 0230 EN

14 Functional Safety Supplementary manual for series SK 200E 3.3 Safety functions WARNING Mechanical brake failure Control of a mechanical brake by means of the frequency inverter is not fail-safe! Triggering of the "STO" function causes the application of a mechanical brake which is controlled by the frequency inverter. The brake takes on the entire load of the drive units with all of its rotating masses and attempts to stop it. A brake which is not designed for this (e.g. a holding brake) may be damaged and may fail. This can result in severe or even fatal injuries or damage to the system, e.g. due to falling loads (lifting gear). Therefore, with the use of a brake This must be designed as an operating brake, or It must be ensured that the drive unit is stopped before the "STO" function is activated. NOTICE: Destruction of the IGBTs Actuation of an electro-mechanical brake by the digital function "Release brake manually" can result in the destruction of the IGBTs for the brake rectifier if the "Safe Stop" function is triggered in the frequency inverter. As a result of this, the brake would no longer be able to be controlled. The brake would be applied. To prevent this, the digital function "Block Voltage" must be triggered before the Safe Stop is triggered Safe Torque Off, STO With the STO function the drive torque is switched off as quickly as possible (see Technical Data Reaction Time) and the drive (motor and machine) runs down to a standstill. This behaviour corresponds to stop category 0 (uncontrolled braking) according to EN Therefore an undefined time elapses before the drive unit does not carry out any further hazardous movement and a safe state is achieved. Detection of whether or when the drive unit has achieved a safe state is not integrated into the frequency inverter. Depending on the switching equipment used and the use of a safe shut-down method, an STO function with Safety Category 4 as per DIN EN ISO can be implemented Safe Stop 1, SS1 With the function SS1 the motor is initially braked by the frequency inverter. After standstill, the function STO is switched to. This behaviour corresponds to stop category 1 (controlled braking) according to EN Switching to the STO function can be monitored after reaching standstill or can be carried out via a fail-safe timing relay (delayed output of a safety circuit device). Information Controlled braking Controlled braking is triggered via a digital input and only complies with low safety requirements! If controlled braking fails, the function switches over to STO. If necessary, the braking process must be monitored. 14 BU 0230 EN-1217

15 3 Function description 3.4 Examples / Implementation The following illustrates several examples of solutions for the safety functions STO and SS STO function Implementation of a safety function usually requires the use of a protective switching device. The safety category of the function is determined by the component with the lowest category. Emergency stop button Safety switching device Shielded cables 1) Frequency inverter Reset "safe pulse block" Use of the or Switch-off of the 24 V supply 1) Shielded cables to eliminate errors as per DIN EN ISO Supply voltage 2 Reset circuit 3 Input circuit with cross-circuit detection 4 Safety output In this example, Safety Category 4 as per DIN ISO can be achieved. The prerequisite for this is that the emergency stop button, the protective switching device and the wiring fulfil the requirements for Category 4. For example, this can be achieved as follows: Redundant protective switching device with self-monitoring Dual-channel input circuit with cross-wire recognition (and appropriate emergency stop button) Safety output with periodic switch-off tests (OSSD) Exclusion of faults as per DIN ISO for the wiring between the switching device and the input terminals of the safe shut-down method, by the use of a shielded cable and connection of the shield at both ends. If the "Safe Pulse Block" is triggered for an enabled frequency inverter, this results in an error E018 (18.0 "Safety Circuit "). To prevent this, the digital input DIN4 can be parameterised with the function "10" ("Block Voltage"). For devices with "Safe Pulse Block", SK 210E, SK 215E, SK 230E and SK 235E), the digital input DIN4 is not implemented as a separate physical input, but rather is in parallel with the "Safe Pulse Block" and serves as a diagnostic path for the status of the safe pulse block at the input terminals. BU 0230 EN

16 Functional Safety Supplementary manual for series SK 200E The typical reaction time can be reduced by the additional use of a digital input. A second safety output is required to control the digital input. This solution is preferable, especially in cases where the switching device only checks its safety outputs in the course of an enabling cycle, as is the case with some electro-mechanical switching devices. A suitable checking interval must be specified according to the safety requirements. Emergency stop button Safety switching device Shielded cables 1) Frequency inverter Reset "safe pulse block" Use of the or Switch-off of the 24 V supply 1) Shielded cables to eliminate errors as per DIN EN ISO Supply voltage 2 Reset circuit 3 Input circuit with cross-circuit detection 4 Safety output 1 5 Safety output 2 6 Filter for OSSD (optional) only necessary in environments with high levels of interference A separate shielded cable must be used for connecting each of the safety outputs! However, with the use of a protective switching device with cross-circuit monitoring of OSSD outputs, the cables of both safety outputs can also be run in a common shielded cable. The requirements for Safety Category 4 are only fulfilled by the "Safe Pulse Block"and the "shutdown of the 24 V supply" function. The digital inputs (DIN1... DIN4) only achieve Safety Category 1 and PL c (Performance Level c). During the period between activation of the safety function via a digital input and activation of the STO via the connections "24 V SH" and "GND SH" the frequency inverter can also only fulfil Safety Category 1 and PL c. 16 BU 0230 EN-1217

17 3 Function description SS1 Function A digital input is always necessary in order to implement the SS1 function. With this digital input, a braking action is initiated by the frequency inverter. For this, the digital input is parameterised to the function "11"(Fast Stop). Emergency stop button Safety switching device Shielded cables 1) Frequency inverter Reset "safe pulse block" Use of the or Switch-off of the 24 V supply 1) Shielded cables to eliminate errors as per DIN EN ISO Supply voltage 2 Reset circuit 3 Input circuit with cross-circuit detection 4 Safety output 1 (delayed) 5 Safety output 2 6 Filter for OSSD (optional) only necessary in environments with high levels of interference Actuation of the emergency stop button (call-up of the safety function) initially triggers a controlled braking action via a digital input "DIN". In this case it must be ensured that the drive is brought to standstill within the parameterised fast stop time P426. After a delay time which is controlled by a protective switching device, STO is triggered. The delay time must be dimensioned so that the delay is longer than the fast stop time plus the DC run-on time P559. The delay time must be selected so as to be fail-safe. After the delay time which is set in the protective switching device has elapsed, the frequency inverter always switches to the STO function. This also applies in the case of failure of the controlled braking action. A separate shielded cable must be used for connecting each of the safety outputs! However, with the use of a protective switching device with cross-circuit monitoring of OSSD outputs, the cables of both safety outputs can also be run in a common shielded cable. The requirements for Safety Category 4 are only fulfilled by the "Safe Pulse Block"and the "shutdown of the 24 V supply" function. The digital inputs (DIN1... DIN4) only achieve Safety Category 1 and PL c (Performance Level c). BU 0230 EN

18 Functional Safety Supplementary manual for series SK 200E During the period between activation of the safety function via a digital input and activation of the STO via the connections "24 V SH" and "GND SH" the frequency inverter can also only fulfil Safety Category 1 and PL c. 18 BU 0230 EN-1217

19 3 Function description Simple restart block Safety Category 4 as per DIN ISO can be achieved with a direct dual-channel triggering of the "Safe Pulse Block" with the aid of a safe switching element. The following illustration shows an example with an emergency stop switch (positively opening contacts, Safety Category 4). Emergency stop button Shielded cables 1) Frequency inverter 1) Shielded cables to exclude faults as per DIN EN ISO To achieve Safety Category 4, fault exclusion as per EN Section D.5 must be possible for the upstream components (hard-wiring and dual-channel button with independent, positive-opening contacts) i.e., in this example, the emergency-stop button and the wiring must be designed in such a way that short-circuiting at the emergency-stop button and to other live systems can be ruled out. In this example, there is no reset circuit as is the case with the protective switching devices. If the result of risk analysis is that cancellation of the stop command must be acknowledged by intended manual action, then the resetting requirements can be fulfilled organisationally (e.g. by an emergency stop button with key releasing device and storage of the key away from the machine). If the "Safe Pulse Block" is triggered for an enabled frequency inverter, this results in an error E018 (18.0 "Safety Circuit "). Information Functions P428 and P506 With use of the function P506 "Automatic Fault Acknowledgement" And P428 "Automatic Start" (refer to the description in the manual BU 0200) the drive unit starts immediately after the emergency stop button has been released. Because of this, it is urgently recommended that these functions are not used in combination and especially not for safety-relevant applications. BU 0230 EN

20 Functional Safety Supplementary manual for series SK 200E Example without safe shut-down method It is only possible to implement the safety functions STO or SS1 with a digital input and a protective switching device. However, with this switching variant, according to DIN EN ISO the maximum safety category which can be achieved is Safety Category 1. However, the condition for this is that in addition to the digital input, all other components (protective switching device, emergency stop button, wiring) also fulfil the requirements for Category 1. Emergency stop button Protective switching device Shielded cables 1) Frequency inverter Reset Use of a digital input 1) Shielded cables to exclude faults as per DIN EN ISO Supply voltage 2 Reset circuit 3 Input circuit with cross-circuit detection 4 Not available 5 Safety output 6 Filter for OSSD (optional) only necessary in environments with high levels of interference To implement the safety function STO, the digital input is parameterised to function "10" (Block Voltage). For the safety function SS1 the digital input is parameterised with function "11" ("Fast Stop"). The fast stop time is set via parameter P426. It must be ensured that the drive is actually brought to standstill within the parameterised fast stop time. Information Safety category Implementation of safety switching without a safe shut-down method (as described above) only enables compliance with Safety Category 1 (or Performance Level c) as a maximum. This switching variant also does not have SIL capability ( Section 8.2 "Safety categories") This switching version should therefore only be considered if only low requirements for functional safety need to be fulfilled and if the risk assessment has shown that failure of the safety function can only result in slight (usually temporary) injuries (Section 8.2 "Safety categories"). In case of doubt, a safe shut-down method should always be used ( Section 3.1 "Safe shut-down methods") 20 BU 0230 EN-1217

21 3 Function description Ruling out wiring faults In the examples above, a separate shielded cable, whose shield is connected at both ends is used for each of the inputs which are used for the implementation of the safety function (see also the following illustration). These measures serve to rule out faults as per DIN EN ISO in case of a short circuit between any of the conductors. This exclusion of faults is necessary in order to fulfil the requirements of Safety Category 4 as per DIN EN ISO This means that, neither a single detected fault or an accumulation of undetected faults can result in the loss of the safety function. A short circuit from an external voltage, e.g. from a 24V control cable, to the 24V input of a safe shut-down method could lead to the loss of a safety function i.e. this fault must be prevented by means of suitable measures. The use of a separate shielded cable for each input is not mandatory. For example, the cables for the digital inputs and the safe shut-down method may be jointly run in a shielded cable, if the monitored safety outputs of the switching device are equipped with cross-circuit detection (see the following illustration). If necessary, the effectiveness of the short-circuit detection must be demonstrated. Safety output on the safety switching device Shielded cables 1) "safe pulse block" Frequency inverter Use of the or Switch-off of the 24 V supply Monitored outputs without cross-wire monitoring Output 1 Output 2 Monitored outputs with crosswire monitoring Output 1 Output 2 1) Shielded cable to exclude faults as per DIN EN ISO , for connection of the safety outputs to a digital input with optional filter for OSSD (only necessary in environments with high levels of interference). Other measures (separate cable duct, installation in armoured conduit, etc.) are possible. More precise details result from the risk assessment and the FMEA for the specific application. For the "Safe Pulse Block" it is also conceivable that this is triggered via two safety outputs, one switching the 24 V output and the other switching the GND output. BU 0230 EN

22 Functional Safety Supplementary manual for series SK 200E Safety output on the safety switching device Connection cable Frequency inverter Use of the "safe pulse block" Monitored outputs Output 1 Output 2 In this case a shielded cable is not strictly necessary if both safety outputs are monitored. If, for example, other 24V control cables are laid in the same cable duct and a fault in the form of a shortcircuit from 24V_SH to a control cable (=24 V) is assumed, this fault would be detected by the output monitoring of the switching device and the "Safe Pulse Block" would be triggered by the second safety output. More precise details result from the FMEA for the specific application. If a shielded cable is not used for the wiring of the safety function, the effects of electromagnetic fields may need to be taken into account. Hence the use of a 1 m long cable (in a separate cable duct) in an environment without strong electromagnetic fields is relatively safe, while the installation of a long cable in the direct vicinity of a powerful transmitter or a medium voltage distributor may cause the failure of the safety function. Because of this, the use of shielded cables is generally recommended. 22 BU 0230 EN-1217

23 4 Assembly and installation 4 Assembly and installation The installation instructions contained in this manual only deal with issues that are related to functional safety. For further information, please refer to the manual for the relevant frequency inverter (BU 0200). 4.1 Installation and assembly The installation instructions in BU 0200 must be observed! 4.2 Electrical connection The information for installation or electrical connection from the manual BU 0200 as well as all of the following information must be observed. WARNING Electric shock Touching electrically conducting components may cause an electric shock and severe or possibly fatal injury. Disconnect the frequency inverter from the power supply before starting installation work. Only work on devices which have been disconnected from the power supply. WARNING Electric shock The frequency inverter carries hazardous voltage for up to 5 minutes after being switched off. Only start work after a waiting period of at least 5 minutes after switching off the mains supply (disconnection) Wiring guidelines The wiring guidelines from the frequency inverter manual (BU 0200) apply! Mains connection Devices which implement a safety function may only be operated on TN and TT networks. The equipment has not been designed for operation at IT and "Grounded Corner" networks. BU 0230 EN

24 Functional Safety Supplementary manual for series SK 200E Control cable connections In order to access the electrical connections, the SK 2xxE must be removed from the SK TI4- connection unit. One terminal block is provided for the power connections and one for the control connections. The PE connections (device-earth) are inside the cast housing of the connecting unit on the base. A contact is available on the power terminal block for size 4. The terminal strip assignments differ according to the version of the device. The correct assignment can be found on the inscription on the respective terminal or the terminal overview plan printed inside the device. Connecting terminals for (1) Power cable Motor cable Brake resistance lines (2) Control lines Electromechanical brake PTC (TF) of motor (3) PE 24 BU 0230 EN-1217

25 4 Assembly and installation Control terminal details Labelling, function SH: Function: Safe stop DOUT: Digital output AS1+/-: Integrated AS interface 24 V SH: "Safe stop" input 24 V: 24 V DC control voltage 0 V SH: "Safe stop" reference potential 10 V REF: 10 V DC reference voltage for AIN AIN +/- Analogue input AGND: Reference potential for analogue signals SYS H/L: System bus GND: Reference potential for digital signals MB+/-: Control of electro-mechanical brake DIN: Digital input TF+/-: Motor thermistor (PTC) connection Connections depending on the development stage Detailed information regarding functional safety (Safe Stop) can be found in supplementary manual BU Sizes SK 200E SK 210E SK 220E SK 230E Device type SK 205E SK 215E SK 225E SK 235E SH AS1 SH+AS1 Labelling Pin SH AS1 SH+AS1 24 V (output) V (input)* AIN1+ ASI+ 14/ /84 24 V (input)* ASI+ AIN GND AGND ASI- 12/ /85 GND ASI- DIN DIN1 DIN DIN2 DIN DIN3 DIN4 24 V SH DIN4 24 V SH 24/ /89 DIN4 24 V SH DIN4 24 V SH GND 0V SH GND 0V SH 40/ /88 GND 0V SH GND 0V SH DOUT DOUT1 GND GND SYS H SYS H SYS L SYS L 10 V REF DOUT MB+ GND MB- TF TF+ TF TF- * when using the AS interface, terminal 44 provides an output voltage (24 V, max. 60 ma). In this case, no voltage sources may be connected to this terminal! BU 0230 EN

26 Functional Safety Supplementary manual for series SK 200E Size 4 Device type SK 200E SK 210E SK 220E SK 230E (SH) (ASI) (SH+ASI) Pin Labelling V (output) V (output) 3 40 GND 4 40 GND 5 -/84 / ASI+ 6 -/85 / ASI V REF 8 14 AIN AIN AGND V (input) V (input) GND GND DIN DIN DIN /89 DIN4 24 V SH DIN4 24 V SH 19 40/88 GND 0V SH GND 0V SH GND 21 1 DOUT GND 23 3 DOUT GND SYS H SYS L TF TF- Separate terminal block (2-pole): 1 79 MB MB+ 26 BU 0230 EN-1217

27 Meaning, Functions Terminal Description / Technical data Parameter 4 Assembly and installation No. Designation Meaning No. Function of factory setting Digital outputs Signalling of device operating statuses 24 V DC With inductive loads: Provide protection via free-wheeling diode! Maximum load 20 ma 1 DOUT1 Digital output 1 P434 [-01] Fault 3 DOUT2 Digital output 2 P434 [-02] Fault Notes: Size 4: Max. load 50 ma SK 2x5E: Voltage level depending on input voltage level (18 30 V DC) Information Digital output A digital output can be used to indicate the status of the "Safe Pulse Block". It should be noted that this status indication is not fail-safe. Information Digital output for "switch-off of the 24 V supply" If "switch-off of the 24V supply" is selected as the safe shut-down method, the digital output may not be able to be used, as it is also switched off with the 24 V supply. It must also be ensured that no external voltage is introduced via the digital output. Digital inputs Actuation of device via an external controller, switch or the like, connection of HTL transmitter (DIN2 and DIN3 only) as per EN , type 1 Low: 0-5 V (~ 9.5 kω) High: V (~ kω) Scan time: 1 ms Reaction time: 4-5 ms Input capacitance 10 nf (DIN1, DIN 4) 1.2 nf (DIN 2, DIN 3) DIN 2 and DIN 3 double allocation Min.: 250 Hz, Max.: 205 khz 21 DIN1 Digital input 1 P420 [-01] ON right 22 DIN2 Digital input 2 P420 [-02] ON left 23 DIN3 Digital input 3 P420 [-03] Fixed frequency 1 ( P465[-01]) 24 DIN4 Digital input 4 P420 [-04] Fixed frequency 2 ( P465[-02]) Control voltage source Control voltage of device, e.g. for supplying accessories. 24 V DC ± 25 %, short circuit-proof Maximum load 200 ma 1) 43 VO / 24V Voltage output GND / 0V Reference potential GND - - 1) See "Total currents" information ( BU 0200) Note: Size 4: Max. load 500 ma BU 0230 EN

28 Functional Safety Supplementary manual for series SK 200E Control voltage connection Supply voltage for device 24 V DC ± 25 % (size 1 3) 24 V DC + 25 % (size 4) 200 ma 800 ma, depending on load of inputs and outputs and use of options 44 24V Voltage input GND / 0V Reference potential GND - - Functional Safety "Safe Stop" Fail-safe input Details: BU0230, Technical data 89 VI/24V SH 24 V input VI/0V SH Reference potential - - Size 4: Automatic changeover between terminal 44 and internal power supply if connected control voltage is insufficient. With use of AS interface: 24 V output voltage, 60 ma. The input is always active. In order to make the device ready for operation, this input must be provided with the required voltage. 4.3 Details of the safe shut-down method Safe shut-down method - Safe Pulse Block A two-wire shielded cable must be used for the "Safe Pulse Block". The shield must be applied on both sides! The voltage drop in the cable must not exceed the following values: Mechanical protective switching device: ΔU Cable 3 V Electronic protective switching device: ΔU Cable 1 V. I IN,Peak ( Section 9 "Technical Data" should be used to calculate the peak current Operation with OSSD The Safe Pulse Block is specially designed for use with an OSSD. The capacity between the wires (including the shield capacities) must not exceed a value of x = 20 nf for each frequency inverter which is connected. The value x is determined as follows: x = 4 nf * t _OSSD / 0.1 ms where t _OSSD = Width of the test pulse, max. 0.5 ms Additional restrictions may apply with regard to the protective switching device EMC The EMC guideline values ( Manual BU 0200) can be complied with EMC-compliant wiring up to a cable length of 100 m between the protective switching device and the frequency inverter. 28 BU 0230 EN-1217

29 4 Assembly and installation Example operation of multiple devices When operating several frequency inverters with one protective switching device, the switching capacity of the switching device and the load rating of the 24 V mains unit must be observed. The shield must be correctly connected ( Illustrations in Section 3.1 "Safe shut-down methods"). The permissible voltage drops in the cable must be observed! Example Given: 4 frequency inverters are connected to an electronic protective switching device. The frequency inverters are located adjacent to each other in a system. 20 m must be bridged between the frequency inverters and the protective switching device. A 2 x 1.5 mm 2 cable is used. The following applies: R ρcu * l q = with IN Peak = ρ CU mm 19Ω * km I, 0.5 A ( Section 9 "Technical Data" ) 2 Solution Double the length of cable must be used because line drops occur in both wires. R 0. 5Ω ΔU Cable = R * No. FU * I IN,Peak = 0.5 Ω * 4 * 0.5 A = 1 V ΔU Cable 1 V o.k Safe shut-down method - 24 V supply If the 24 V supply is used as the safe shut-down method, a dual conductor shielded cable must be used. The shield must be applied on both sides! Information 24 V supply for accessories and options Optional modules such as interfaces for connection to a field bus system (e.g. SK CU4-PBR) and other consumers (e.g. IO extensions, sensors, encoders, etc. must not be supplied via the 24 V supply which is used for the safe shut-down method. The supply for such accessories must be provided by independent power sources. The cable which is used must be dimensioned so that there is a voltage of at least 18V at the input terminals. For operation with an OSSD, a voltage of at least 21.6 V is required. All details with regard to permissible limit values can be found in the Technical Data ( Section 9 "Technical Data") BU 0230 EN

30 Functional Safety Supplementary manual for series SK 200E Input current (without load from DO1)) Maximum input current Typical input current, Size 3 Typical input current, Size 1, 2 Figure 3: Input currents depending on input voltage Voltage at input terminals The input currents shown in the graphs are average values. The typical currents differ according to the size of the FI (see identification code). If a SimpleBox or ParameterBox is connected via the RJ12 control block for servicing (see Manual BU 0200), the resulting current requirement of approx. 50 ma must also be taken into account. The maximum input current is derived from the rated power of the internal mains unit. The peak current on switch-on is double the maximum input current. 30 BU 0230 EN-1217

31 4 Assembly and installation Operation at OSSD The 24 V supply is not specially designed for supply via an OSSD. However, it may be operated from an OSSD if the following restrictions are taken into account. A resistor is located in the frequency inverter, in order to discharge the cable with a test pulse from an OSSD. We recommend that a capacitance of 2 nf * t OSSD / 0.1 ms (including shielding capacitance) per connected frequency inverter is not exceeded (with t OSSD = Width of test pulse, max. 0.5 ms) Additional restrictions may apply here with regard to the protective switching device. As with operation from an OSSD, there is an interruption in the supply during a test pulse, the supply voltage inside the device reduces during the test pulse. In order to ensure correct operation, the resistance of the connected cable (internal resistance of the source) should not exceed the values in the following diagram. Maximum cable resistance Fig. 4: Maximum permissible cable resistance Source voltage The permissible cable resistance depends on the source voltage and the load on the digital output DO1. Even with higher source voltages (up to 30 V) it should not exceed a value of 3 Ω. Operation from an OSSD is possible above a source voltage of 20 V. However, a source voltage of at least 21.6 V is recommended. Especially if several inverters are connected to a protective switching device, care must be taken that there is at least 21.6 V at the terminals of the inverter. With operation by an OSSD, both the mains unit and the digital output DO1 are supported by the input capacitors during a test pulse. After the test pulse, the supporting capacitance (200 µf) is recharged by means of a relatively large peak current. The graphs shown here show theoretical maximum values (for an frequency inverter with power 7.5 kw, 400 V). In practice, the currents are somewhat lower. BU 0230 EN

32 Functional Safety Supplementary manual for series SK 200E Peak current Figure 5: Peak current (without load from DO1) Cable resistance Peak current Figure 6: Peak current (load of 200mA on DO1) Cable resistance This current only occurs for a short time after a test pulse from an upstream protective switching device and reduces according to the DC resistance of the cable used. Care should be taken that both the protective switching device (with OSSD) and the feed source can withstand this current. 32 BU 0230 EN-1217

33 4 Assembly and installation EMC The EMC guideline values ( Manual BU 0200) can be complied with EMC-compliant wiring up to a cable length of 100 m between the protective switching device and the frequency inverter Example operation of multiple devices For devices with two 24 V and two GND terminals the cables can be looped through the terminals up to a total current of 6 A. For larger total currents, the two conductors (incoming and outgoing) must be clamped under a single terminal (if necessary with TWIN wire end sleeves). When operating several frequency inverters with one protective switching device, the switching capacity of the switching device and the load rating of the 24 V mains unit must be observed. The shield must be correctly connected ( Illustrations in Section 3.1 "Safe shut-down methods"). The permissible line drops on the cable must be observed! Example Given: 6 frequency inverters are connected to an electronic protective switching device. The frequency inverters are located adjacent to each other in a system. 20 m must be bridged between the frequency inverters and the protective switching device. A 2 x 1.5 mm 2 cable is used. The following applies: R ρcu * l q = with ρ CU mm 19Ω * km I, = 0.5 A ( Section 9 "Technical Data" ) IN Peak 2 Solution Double the length of cable must be used because line drops occur in both wires. R 0. 5Ω R Total = R No. = 0.5Ω*6 = 3Ω * FI On comparison of the total cable resistance with the first illustration from Section "Operation at OSSD" it can be seen that an input voltage of at least 22 V is required for a digital output with no load. BU 0230 EN

34 Functional Safety Supplementary manual for series SK 200E 5 commissioning WARNING Electric shock The device is not equipped with a mains switch and is therefore always live when connected to the power supply. Live voltages may therefore be connected to a connected motor at standstill. The voltage supply of the device may directly or indirectly put it into operation, or touching electrically conducting components may then cause an electric shock with possible fatal consequences. WARNING Electric shock There may be a hazardous voltage at the motor connection contacts, even if the Safe Stop ("STO" function) is active. Do not touch any contacts Protect connections which are not required with the cover caps provided Only the specific matters for functional safety during commissioning are considered in the following. For a detailed section for commissioning the FI and its basic or standard functions, as well as all of the necessary FI parameters, please refer to the frequency inverter manual BU For the implementation of a safety function (STO or SS1), in addition to a safe shut-down method, a digital input is used, which should be assigned a special function. Because of this, when commissioning, a PC with an RS232/458 interface, or alternatively a SimpleBox/ParameterBox is required for parameterisation. Configuration by means of the DIP switches alone is not possible. Care must be taken that the DIP switches "I/O" (S1:4 and S1:5) are in the position "0" ("Off")(Factory setting). It is only in this position that the digital inputs can be assigned the function "10" (Block Voltage") or "11" (Fast Stop) via the parameters P420 [-01] to [-04]. The setting of the DIP switches can be checked via parameter P DIP switch S1 (8-pole) 2 Plug-in EEPROM ""Memory Module") 34 BU 0230 EN-1217

35 5 commissioning 5.1 Commissioning steps for STO A safety output of the protective switching device is connected to a safe shut-down method ( Section 3.1 "Safe shut-down methods"). Depending on the required safety category, if necessary, a wiring fault (short-circuit between any particular wires) must be able to be excluded. It is recommended that a two-conductor shielded cable is used for the safe shut-down method and that the shield is correctly connected ( Section "Ruling out wiring faults"). The typical reaction time can be reduced by the additional use of a digital input. With the Safe Pulse Block, the diagnostic path "Status at the input terminals", which is in the form of Digital Input 4 parallel to the Safe Pulse Block, can be used. For this, digital input 4 is parameterised with function "10" (Block Voltage). Another digital input may be used, however, in this case the different reference voltages must be observed. With switch-off of the 24 V supply an additional digital input is always required in order to reduce the reaction time. It is recommended that a separate shielded cable is used for each safe shut-down method and for the digital inputs used for functional safety, and that the shields are correctly connected ( Section "Ruling out wiring faults"). The switching delay of the of the relevant digital input (see parameter P475) must not be used (setting "0"). Depending on the application, disabling of the safety function may cause a hazard, so that a monitored start is necessary. In this case the "Automatic Start" (P428) must not be used (setting "0"). 5.2 Commissioning of SS1 A safety output of the protective switching device is connected to a digital input( Section "SS1 Function"). It is recommended that a two-conductor shielded cable is used and that the shield is correctly connected ( Section "Ruling out wiring faults"). A safe shut-down method is connected to a time-delayed safety output of the protective switching device. ( Section 3.1 "Safe shut-down methods"). It is recommended that a separate two-wire shielded cable is used for this. The cable shield must be connected at both ends ( Section "Ruling out wiring faults"). The selected digital input must be parameterised with function "11" (Fast Stop). WARNING Danger of injury due to failure of SS1 The braking characteristics of the drive unit can be influenced by various factors. Therefore, the mode "Safe Stop 1" may possibly not be correctly complied with. In order to prevent hazards due to this, by means of a final validation in the course of commissioning it must be demonstrated that with the particular settings the requirements for the special intended use are fulfilled, and that the device will at no time be operated outside of its rated data. For the function SS1, parameter P426 (Fast Stop Time) and if necessary P559, "(DC run-on time) must be parameterised according to the requirements of the application. The delay time of the delayed safety output of the protective switching device must be rated so that it is longer than the fast stop time plus the DC run-on time. BU 0230 EN

36 Functional Safety Supplementary manual for series SK 200E The actual stopping time for the drive unit depends on various factors. It may deviate for the parameterised fast stop time P426) if, for example, one or more of the following events occur during the active fast stop. Achievement / Exceeding of the power limits of the FI Achievement / Exceeding of one or more parameterised limit values, (e.g.: P112, P536, P537) Use of direct current braking (function "Immediate DC Braking") in parameter P108. With the use of the shut-down mode "Immediate DC Braking" the fast stop time is not taken into account. The same braking time (resulting from the settings in P109, P110) is used as for shutdown. In unfavourable cases, the drive unit cannot be braked to a standstill during the parameterised fast stop time. Before the elapse of the parameterised fast stop time it switches to the the "Safe Torque Switch Off" mode (STO) and runs to a standstill. The switching delay of the of the relevant digital input (see parameter P475) must not be used (setting "0"). Depending on the application, disabling of the safety function may cause a hazard, so that a monitored start is necessary. In this case the "Automatic Start" (P428) must not be used (setting "0"). 5.3 Selection of the safe shut-down method The following comparison summarises the essential differences between the two available "Safe Shutdown Methods" Criterion Safe pulse block Switch-off of the 24 V supply Duration of use T M 20 years 5 years Separate earth Yes No Communication with the frequency inverter Possible Not possible possible if the safety function is triggered Diagnosis of the shut-down method Possible Not possible Operation at OSSD Yes Possible with restrictions ( Section ) Information SK 2x0E, Size 4 The 24 V connection in Size 4 SK 200E, SK 210E, SK 220E and SK 230E frequency inverters which is used to supply the control electronics cannot be used as a safe shut-down method. Reason: The high voltage mains which is used in these devices would continue to supply the controller and the micro-controller even when the external 24 V supply is switched off. 5.4 Validation It must be proven by suitable validation that the requirements for the specially intended purpose have been met. 36 BU 0230 EN-1217

37 6 Parameters 6 Parameters The following only lists the specific parameters and display and setting options for the Functional Safety technology function. For a detailed overview of all available parameters, please refer to the frequency inverter manual BU Information Relevant parameters for STO or SS1 In order to implement the function STO, depending on the digital input which is used, the parameters for the digital input must be set to function "10" ("Block Voltage"). For the function SS1 the parameter of the relevant digital input is set to function "11" ("Fast Stop"). In addition, the "Fast Stop Time" must be entered in parameter P426 and the DC Run-on Time" must be entered in parameter P559. For the function SS1 the "Fast Stop Time" must be set so that the drive unit actually comes to a standstill within the stated time. The DC Run-on Time follows after the Fast Stop Time. The delay time of the delayed output of the protective switching device must be set so that it is longer than the parameterised values for the "Fast Stop Time"plus the "DC Run-on Time. 6.1 Description of parameters P000 (parameter number) Operating display (parameter name) xx 1) S P Setting range (or display range) Display of typical display format (e.g. (bin = binary)) of possible setting range and number of decimal places Other applicable parameter(s): List of other parameters that are directly associated Arrays [-01] If parameters have a substructure in several arrays, this is shown here. Factory setting { 0 } Default setting that the parameters typically have in the as-delivered condition of the device or to which it is set after carrying out "Restore factory settings" (see parameter P523). Scope of Application Description Note Setting values (and display values) 1) xx = other identification List of device variants to which this parameter applies. If the parameter is generally valid, i.e. for the entire model series, this line is omitted. Description, functionality, meaning and the like for this parameter. Additional notes about this parameter Figure 7: Explanation of parameter description List of possible settings with description of the respective functions Information Description of parameters Unused lines of information are not listed. Note / Explanation: Code Designation Meaning S Supervisor-Parameter The parameter can now be displayed and modified if the relevant supervisor code has been set (see parameter P003). P Parameter set-dependent The parameter provides different setting options that are dependent upon the selected parameter set. BU 0230 EN

38 Functional Safety Supplementary manual for series SK 200E Control terminals P420 Digital inputs Arrays [-01] [-04] Scope of Application Description (DIN1... DIN4) Assignment of functions for the digital input Setting values Value Meaning 0 Off The input is not used. 10 Disable voltage (coast to stop) The FI output voltage is switched off; the motor runs down freely. Low 11 Emergency stop The FI reduces the frequency according to the programmed fast stop time P426. 1) Low 1) Exception: P108, setting "Immediate DC Braking" With the use of the shut-down mode "Immediate DC Braking" the fast stop time is not taken into account. The same braking time (resulting from the settings in P109, P110) is used as for shut-down. P426 Quick stop time S P Description Setting of the stop time for the fast stop function which can be triggered either via a digital input, the bus control, the keyboard or automatically in case of a fault. The quick stop time is the time for the linear frequency decrease from the set maximum frequency (P105) to 0 Hz. If an actual setpoint <100 % is being used, the emergency stop time is reduced correspondingly. Setting values WARNING! Danger of injury due to failure of SS1 The braking characteristics of the drive unit can be influenced by various factors. Therefore, the mode "Safe Stop 1" may possibly not be correctly complied with. In order to prevent hazards due to this, by means of a final validation in the course of commissioning it must be demonstrated that with the particular settings the requirements for the special intended use are fulfilled, and that the device will at no time be operated outside of its rated data. P428 Automatic starting S P Setting range 0 1 Description Decision as to whether the frequency inverter should react to an enable signal. Setting values Value Meaning 0 Off The device expects a flank (signal change "low high") at the digital input which has been parametrised to "Enable" in order to start the drive. If the device is switched on with an active enable signal (mains voltage on), it immediately switches to "Switch-on block). 1 On The device expects a signal level ("high") at the digital input which has been parametrised to "Enable" in order to start the drive. NOTICE! Danger of injury! Drive starts up immediately! 38 BU 0230 EN-1217

39 6 Parameters P434 Digital output function Arrays [-01] [-02] Description Assignment of functions for the digital output Setting values Value Meaning 0 Off The output is not used. 01 External brake For control of a mechanical brake on the motor. For details see BU 0200 WARNING: Brake failure! The control is not fail-safe! Design the brake as an operating brake. Ensure that the drive is brought to a standstill before "STO" becomes active. 07 Fault General error message. For details see BU Digital-In 4 status The status of digital Input 4 is depicted. For devices with functional safety this corresponds to the status "Safe pulse block" on the input terminals. 39 STO inactive This function depicts the reaction of the "safe pulse block". The signal drops (High Low) when STO and Safe Stop are active. P481 Function BusIO Out Bits S Arrays [-01] [-10] Description Assignment of functions for Bus IO Out Bits. The Bus IO In Bits are treated as digital outputs by the frequency inverter. Setting values Value Meaning 0 Off The output is not used. 01 External brake For control of a mechanical brake on the motor. For details see BU 0200 WARNING: Brake failure! The control is not fail-safe! Design the brake as an operating brake. Ensure that the drive is brought to a standstill before "STO" becomes active. 07 Fault General error message. For details see BU Digital-In 4 status The status of digital Input 4 is depicted. For devices with functional safety this corresponds to the status "Safe pulse block" on the input terminals. 39 STO inactive This function depicts the reaction of the "safe pulse block". The signal drops (High Low) when STO and Safe Stop are active. BU 0230 EN

40 Functional Safety Supplementary manual for series SK 200E Additional parameters P506 Automatic fault acknowledgement S Description Automatic acknowledgement of fault messages. (For details see BU 0200) Note Setting values Automatic error acknowledgement should not be used in association with a safety function. 0 = Detection is disabled P550 EEPROM copy order Description The data sets saved in the internal EEPROM and in the Memory Module can be copied between the devices. This includes a PLC program that is present on the device. Note The device always uses the data record which is saved in the internal EEPROM. With older versions ( V1.4 R1) the data record of the external EEPROM (memory module) is used. The parametrisation of the internal EEPROM was only used if no Memory Module was plugged in. WARNING! Loss of safe function. After parameters have been copied the safe functions must be revalidated. This is the only way to ensure that the safety functions operate correctly. Setting values Value Meaning 0 No change 1 External Internal The data set is copied from the memory module (external EEPROM) to the internal EEPROM. 2 Internal External The data set is copied from the internal EEPROM to the memory module (external EEPROM). 3 External Internal Exchange data sets, the data sets are exchanged between the two EEPROMs P559 DC run-on time S P Setting range Description s Completion of a braking action by temporary connection of a DC voltage to the motor connection terminals. (For details see BU 0200) 40 BU 0230 EN-1217

41 7 Operating status messages 7 Operating status messages The majority of frequency inverter functions and operating data are continuously monitored and simultaneously compared with limiting values. If a deviation is detected, the inverter reacts with a warning or an error message. Basic information on this topic is contained in the manual for the device. All faults or reasons which may result in a switch-on block of the frequency inverter and which are associated with the STO function are listed below. WARNING Loss of safe function In case of an EEPROM fault, the digital input functions (DIN1... DIN4) "Block Voltage" and "Fast Stop" may not function or may function incorrectly. After an EEPROM fault, the digital inputs associated with safety functions must be revalidated. This is the only way to ensure that the safety functions operate correctly. Error messages Display in the SimpleBox / ControlBox Group Details in P700 [-01] / P701 Fault Text in the ParameterBox Cause Remedy E Parameter loss (maximum EEPROM value exceeded) Error in EEPROM data Software version of the stored data set not compatible with the software version of the FI. NOTE: Faulty parameters are automatically reloaded (default data). EMC interferences (see also E020) 8.1 Inverter type incorrect EEPROM faulty 8.2 Reserved 8.3 EEPROM KSE error (Customer interface incorrectly identified (customer s interface equipment)) 8.4 Internal EEPROM error (Database version incorrect) The upgrade level of the frequency inverter was not correctly identified. EEPROM with a firmware status of version 1.2 or above plugged in to an FI with older firmware status Loss of parameters! (see also Information in section ) Switch mains voltage off and on again. 8.7 EEPR copy not the same E Safety circuit While the frequency inverter was enabled, the Safe Pulse Block safety circuit was triggered. BU 0230 EN

42 Functional Safety Supplementary manual for series SK 200E Switch-on block messages Display in the SimpleBox / ControlBox Group Details in P700 [-03] Reason: Text in the ParameterBox Cause Remedy I STO active The Safe Pulse Block safety circuit has been triggered. A connected motor does not produce any torque. Status information It is possible to access status information by means of the ParameterBox, SimpleBox or via a field bus. This information is not provided on a fail-safe basis, but rather only for information purposes! The status of the "Safe Pulse Block" and the digital inputs and outputs can be accessed via the information parameters and if necessary by means of the status word with communication via a field bus. In order to be able to query the reaction of the "Safe Pulse Block", the digital output, a Bus Out bit or a free bit of the status word (Bit 10 or Bit 13) must be assigned the function 39" (STO inactive). The status of this bit can be read out via the parameters P711 ("Relay Status") P741 [-01] ("Status Word" or P741 [-05] ( Bus Out Bits") or transferred via the bus protocol. For the "Safe Pulse Block" both the status of the input terminals (24V_SH, GND_SH) as well as the reaction of the Safe Pulse Block can be queried. No detailed status information is available for the shut-down method "Switch-off of the 24 V supply", as if this shut-down method is used, the supply voltage to the control electronics of the frequency inverter is switched off. With the 24V supply switched off, the status LED DS (Drive Status) is off and no communication with the Frequency inverter is possible. 42 BU 0230 EN-1217

43 8 Additional information 8 Additional information 8.1 Protective switching devices The safety switching device used for the intended purpose, as well as all additional components required to implement a safety function, must fulfil the requirements of the special application in accordance with the risk analysis. The switching device outputs must fulfil the following basic conditions Output voltage The stated voltage must be connected to the input terminals of the frequency inverter i.e. the voltage drop in the cable which is used must be taken into account Mechanical protective switching device 24 V ± 25 % (18 V 30 V) Electronic protective switching device with OSSD outputs 24 V - 20 % / + 25 % (19.2 V 30 V) for the "safe pulse block" 24 V - 10 % / + 25 % (21.6 V 30 V) for "switch-off of the 24 V supply" Switchingcapacityandcurrentload The safety outputs of the switching devices must be designed for the loads stated below. Load per connected frequency inverter Safe pulse block Switch-off of the 24 V supply Continuouscurrent (meanvalue) Sizes 1 to 3 Size 4 (Digital output DO1 without load) 125 ma 40 ma 500 ma ( Section 4.3.2) Switch-on current 500 ma, fort 2 ms 250 ma, fort 2 ms 1 A, t 10 ms, delayed ( Section 4.3.2) Supporting capacitance (downstream of inverse polarity protection) 20 μf 10 μf 200 μf Peak current after an OSSD test pulse (periodic) 500 ma, fort 300 μs 250 ma, fort 250 μs 4.3 ma (with 21.6 V) ( Section 4.3.2) Information Increased current on switch-on or after a test pulse from an OSSD Due to the smoothing capacitors of the safe shut-down method, there is an increased current consumption on switch-on and after a test pulse from an OSSD. The "safe pulse block" is equipped with an active current limiter in order to reduce the load on safety outputs to a minimum. On the other hand, the 24 V supply only has controlled starting characteristics and therefore a limited start-up current. However, after an OSSD test pulse, a relatively large peak current occurs, which is only limited by the input impedance and the source impedance. This results in the limited usability of "Switch off of the 24 V Supply" with an OSSD ( Section 4.3.2) BU 0230 EN

44 Functional Safety Supplementary manual for series SK 200E OSSD outputs, test pulses t off 0.5 ms (width of test pulse) Maximum time in which the output of the protective switching device is switched off for test purposes. D 90 % (duty, switch-on ratio) The supply voltage is applied for at least 90% of the time i.e. for a test pulse of t off =0.5 ms, the supply voltage is subsequently connected for at least t on =4.5 ms. Double pulses are permissible if the two pulses are at least 1µs apart and the condition for D is fulfilled. Permissible test pulses for an OSSD The following sequence results at maximum pulse width: First test pulse with t off= 0.5 ms, Subsequently the supply voltage is applied for 0.5 ms, Followed by the second test pulse with t off= 0.5 ms, After this the supply voltage is applied for at least 8.5 ms! 44 BU 0230 EN-1217

45 8 Additional information 8.2 Safety categories IEC :2005 (German version EN :2006) The requirements of a Category 0 and Category 1 stop function can be fulfilled by the "safe pulse block". The controlled braking of a Category 1 stop function is not fail-safe via the standard functions of the frequency inverter. The switch-over to the stop function of Category 0 is fail-safe IEC :2007 (German version EN :2007) The requirements for the functions "Safe Torque Switch Off" (STO) and "Safe Stop 1" (SS1) can be fulfilled with the shut-down method "Safe Pulse Block. With the function SS1, there is no safe monitoring of motor speed reduction or motor speed reduction by the frequency inverter. If a risk analysis has shown that monitoring is necessary, this must be carried out via an external safe control unit. The solutions for the function SS1 described in the examples correspond to characteristics as per IEC :2007, Section , Paragraph c) "Triggering of motor speed reduction and triggering of the STO function after an application-specific time delay". The motor speed reduction is carried out via the standard functionality of the frequency inverter and is not fail-safe. The switch-over to the STO function is fail-safe IEC 61508:2010 (German version EN 61508:2010) For the safety-relevant stop functions STO and SS1 (designation as per IEC :2007), frequency inverters with the safe shut-down methods according to this manual fulfil the requirements for SIL 3. The controlled braking action of the stop function SS1 does not have SIL capability. ( Section 9.1 "Data for the safe pulse block") ( Section 9.2 "Data for switching off the 24 V supply") Information The digital inputs do not have SIL capability Digital inputs BU 0230 EN

46 Functional Safety Supplementary manual for series SK 200E ISO :2015 (German version EN ISO :2016) For the safety-relevant stop functions, STO and SS1 (designation as per IEC :2007), frequency inverters with the safe shut-down methods according to this manual fulfil the requirements for Performance Level e. With this, Safety Category 4 can be achieved. ( Section 9.1 "Data for the safe pulse block") ( Section 9.2 "Data for switching off the 24 V supply") The digital inputs (DIN1... DIN4) which are used for the implementation of safety-relevant stop functions are primarily intended as auxiliary inputs and can fulfil the requirements of Safety Category 1 and Performance Level c. ( Section 9.3 "Data for the digital inputs") Information Evaluation of safety function The values stated in the Technical Data ( Section 9 "Technical Data") only refer to the stated inputs or shutdown methods. The components which are additionally required for the implementation of a safety function, such as a protective switching device, an emergency stop button etc. must also be taken into account for the evaluation of the safety function. The resulting safety-relevant data can be significantly influenced by these components. 46 BU 0230 EN-1217

47 9 Technical Data 9 Technical Data The Technical Data from the frequency inverter manual (BU 0200) apply! In deviation from this: Function Max. installation altitude above sea level Specification 2000 m The following technical data also apply. BU 0230 EN

48 Functional Safety Supplementary manual for series SK 200E 9.1 Data for the safe pulse block Function Specification Input voltage Sizes 1 to 3 Size V Voltage tolerance ± 25 % (18 V 30 V) Operation at OSSD - 20 % + 25 % (19,2 V 30 V) Power consumption 125 ma 40 ma (mean value) Peak current 500 ma 250 ma (peak, when switching on or at the OSSD) Cable length Line capacitance Switch-on delay Response time Cycle time Requirements made of OSSDs Safety integrity level (IEC 61508) Probability of a hazardous failure per hour Probability of a hazardous failure on call-up Proportion of safe failures 100 m 20 nf per connected frequency inverter ( 4 nf * t _OSSD / 0.1 ms (with t _OSSD max. 0.5 ms)) 200 ms 300 ms ( 65 ms typical) 1 s Test pulse width 500 µs Duty (High level) 90 % Time between double 1 ms (observe the duty factor) pulses SIL 3 PFH = 0 PFH =.,0058 FIT = 5.8*10-12 /h PFD = 0 PFD = 5.23*10-5 SFF = 100 % SFF > 99 % Safety category Category 4 (as per EN ISO ) Performance Level (as PL e per EN ) The mean time until a MTTF d = "High" (>100 years) hazardous failure Degree of diagnostic cannot be established DC > 99 % coverage (DC) (PFH=0) Lifetime TM = 20 years 48 BU 0230 EN-1217

49 9 Technical Data 9.2 Data for switching off the 24 V supply (Only valid for SK 205E and SK 215E Size 1 to 3) Function Input voltage Specification + 24 V Voltage tolerance ± 25 % (18 V 30 V) Operation at OSSD - 10 % + 25 % (21,6 V 30 V) Power consumption Peak current (peak, when switching on or at the OSSD) Cable length Line capacitance Switch-on delay Response time Cycle time Requirements made of OSSDs Safety integrity level (IEC 61508) 500 ma (mean value) 200 ma to 800 ma according to load on the frequency inverter, the inputs and outputs or equipment with options 1 A (Peak on switch-on (after a switch-off time of 1 s)) 6.5 A (Peak, on OSSD) 100 m 2 nf *t OSSD/0,1 ms per connected frequency inverter (with T OSSD = Width of test pulse, max. 0.5 ms) 3 s 200 ms ( 80 ms typical) 4 s Test pulse width 500 µs Duty (High level) 90 % Time between double pulses 1 ms (observe the duty factor) SIL 3 Probability of a PFH = 0 hazardous failure per hour Probability of a PFD = 0 hazardous failure on call-up Proportion of safe SFF = 100 % failures Safety category Category 4 (as per EN ISO ) Performance Level (as PL e per EN ) The mean time until a MTTF d = "High" (>100 years) hazardous failure Degree of diagnostic cannot be established (PFH=0) coverage (DC) Lifetime TM = 5 years BU 0230 EN

50 Functional Safety Supplementary manual for series SK 200E 9.3 Data for the digital inputs Function Input voltage Specification + 24 V Voltage tolerance +- 37,5 % + 25 % (15 V 30 V) High level (V T+) Low level (V T-) Input resistance Input capacitance Scan time Response time Requirements made of OSSDs Safety integrity level (IEC 61508) Probability of a hazardous failure per hour 15 V 30 V 0 V 5 V 9.5 kω (for Low level) 2.5 kω 3.5 kω (for High level) DIN1, DIN4: 10 nf DIN2, DIN3: 1.2 nf 1 ms 5 ms Test pulse width 500 µs Duty (High level) 90 % Time between double pulses The digital inputs do not have SIL capability 1 ms (observe the duty factor) DIN1 and DIN4 PFH = FIT For SK 2x0E in Size 1 to 3 PFH = FIT For SK 2x0E in Size 4 PFH = FIT For SK 2x5E in Size 1 to 3 Proportion of safe failures DIN2 and DIN3 PFH = FIT For SK 2x0E in Size 1 to 3 PFH = FIT For SK 2x0E in Size 4 PFH = FIT For SK 2x5E in Size 1 to 3 DIN1 and DIN4 SFF = % For SK 2x0E in Size 1 to 3 SFF = % For SK 2x0E in Size 4 SFF = % For SK 2x5E in Size 1 to 3 DIN2 and DIN3 SFF = % For SK 2x0E in Size 1 to 3 SFF = % For SK 2x0E in Size 4 SFF = % For SK 2x5E in Size 1 to 3 Safety category Category 1 (as per EN ISO ) Performance Level (as PL c per EN ) The mean time until a MTTF d = "High" (>100 years) hazardous failure Degree of diagnostic No DC coverage (DC) Lifetime TM = 20 years 50 BU 0230 EN-1217

51 10 Appendix 10 Appendix 10.1 Maintenance Instructions The maintenance information from the frequency inverter manual (BU 0200) apply. The information for long-term storage also apply for the Safe Pulse Block. Accordingly, the Pulse Block must be supplied with a voltage of 24 V DC at least 1 x per year for 60 minutes in order to maintain its function and to prevent damage to the Safe Pulse Block Repair information In order to keep repair times as short as possible, please state the reasons for the return of the device and at least one contact partner in case of queries. In case of repairs, please send the device to the following address: NORD Electronic DRIVESYSTEMS GmbH Tjüchkampstraße Aurich, Germany Information Third party accessories Before returning a bus interface and/or a frequency inverter, please remove any external accessories such as mains cables, potentiometers, external displays, etc., which were not supplied by Getriebebau NORD GmbH & Co. KG No liability can be accepted by Getriebebau NORD GmbH & Co. KG for devices which are returned with third party accessories. Information Accompanying document Please use the filled-in accompanying document for returns, You can find this on our homepage or directly under the link Warenbegleitschein. For queries about repairs, please contact: Getriebebau NORD GmbH & Co. KG Tel.: +49 (0) / Fax: +49 (0) / BU 0230 EN

52 Functional Safety Supplementary manual for series SK 200E 10.3 Service and commissioning information In case of problems, e.g. during commissioning, please contact our Service department: Our Service department is available 24/7 and can help you best if you have the following information about the device (e.g. frequency inverter) and its accessories (e.g. bus interface) to hand: Type designation, Serial number, Firmware version 10.4 Documents and software Documents and software can be downloaded from our website Other applicable documents and further information Documentation BU 0200 BU 0000 BU 0040 Contents Manual for frequency inverter NORDAC FLEX SK 200E.. SK 235E Manual for use of NORD CON software Manual for use of NORD parameterisation units Software Software NORD CON Description Parametrisation and diagnostic software 10.5 Certificates The relevant certificates for "Functional Safety" can be downloaded from our internet page Certificates Documentation Contents C Certificates for frequency inverters with "Safe Shut-down Methods" - SK 2x0E, Size 1-3 for frequency inverters NORDAC Flex SK 210E/ SK 230E C Certificates for frequency inverters with "Safe Shut-down Methods" - SK 2x0E, Size 4 for frequency inverters NORDAC Flex SK 210E/ SK 230E C Certificates for frequency inverters with "Safe Shut-down Methods" - SK 2x5E, Size 1-3 for frequency inverters NORDAC Flex SK 205E / SK 215E / SK 235E 52 BU 0230 EN-1217

53 10 Appendix 10.6 Abbreviations AS-i AS Interface BW Braking resistor DIN Digital input DOUT Digital output EMC Electromagnetic compatibility FI Frequency inverter GND Earth OSSD Output Signal Switching Device P Parameter set dependent parameter, i.e. a parameter which can be assigned different functions or values in each of the 4 parameter sets of the frequency inverter. S Supervisor parameter, i.e. A parameter which is only visible if the correct Supervisor Code is entered in parameter P003 SH "Safe Stop" (functional safety) SS1 "Safe Stop 1 STO Safe Torque Off, torque safely switched off SW Software or firmware version of the frequency inverter (can be displayed in parameter P707) BU 0230 EN

54 Functional Safety Supplementary manual for series SK 200E Key word index 2 24 V power supply OSSD V supply...29, 31, 33 Example A Accompanying document AS Interface Auto. Fault acknowledgement (P506) Automatic starting (P428) C Certificates Commissioning SS STO Control terminals Controlled braking D DC run-on time (P559) Digital inputs Digital inputs (P420) Digital output function (P434) Documents other applicable E EEPROM copy order (P550) EMC... 28, 33 Example SS STO Exclusion of faults F Function BusIO Out Bits (P481) Functional Safety I IEC IEC IEC ISO M mechanical brake Messages Fault Operating status O OSSD... 28, 43 P Parameters Protective switching devices Q Quick stop time (P426) R Repair Restart block Returns S Safe pulse block Safe Pulse Block Example Safe Pulse Lock OSSD Safe shut-down method 24 V supply Safe Pulse Block Safe stop Safety functions Safe Stop Safe torque switch-off SS STO BU 0230 EN-1217

55 Key word index Scope of Application... 4 Software SS commissioning example: Standard IEC IEC IEC IEC STO commissioning Example Switch-off of the 24 V supply T Technical Data V Validation BU 0230 EN

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